Hello XT Owners,

I am currently on the road in NT with very minimal access to mechanical service assistance.

The XT has been running fine during the past 5-6 months of ownership.
This afternoon, I attempt to start the XT and the starter did not become energized for a couple seconds while holding the starter button in.
All following attempts to start have failed with no low voltage ticking or other indications of low voltage.

Observations:
Dash light come on as usual.
Neutral light appears stable.
Battery terminals are clean and tight.
Starter relay fuse is good. Also replaced with spare 30A.
All starter relay leads are energized with ignition key on.
No voltage across starter relay with key on and starter switch depressed.
Removed and jumped side stand switch.
The starter does crank with light tester probe across starter relay terminals.

Therefore, I believe the stsrter relay failed.

What is the safest way to jump the starter relay without access to electrical intermittent switch? Is there any risk to simply jumping with a heavy gauge wire? I do not have access to a voltmeter or battery charger. I may try jumping starter button cables.

I will attempt to push start the XT tomorrow. This should prove the battery good.
Otherwise, I may be forced to jump the relay terminals.

Any feedback or suggestions would be appreciated.

Thank you,

David
Pine Creek, NT, Australia

Btw, I am aware of the safety conditions thst must be met to satisfy the safe start condition such as being in neutral, otherwise clutch disgaged, kill switch off, ignition switch on, sidestsnd switch up, etc...

Are there any common failures of the XT that should be investigated first? If necessary, I will investigate each condition that may prevent engaging the starter.

Thanks in advance for any tips or suggedtions.

David

When the wife's TDM 850 starter relay packed in on a tour we used a Leatherman multi-tool's plier tips to bridge the heavy duty starter terminals. Started every time. The pliers were only doing what the inside of the relay (plunger) was failing to do. Gotta say though this diagnosis was only done because we were absolutely certain the solenoid had jammed.

__________________
I have a lot of growing up to do. I realized that the other day inside my fort.

Chalk Two: Hello and thank you for the excellent tip!

I can confirm that a pair of pliers over the two large nuts on the starter solenoid will work. I had a similar problem wild camping in Scotland miles away from anywhere. Fortunately I had a big toggle switch and cobbled together a couple of wires and the switch to make a temporary 'starter' worked well. Ignition on and just flick the switch to start engine, then switch off. Turned out to be a bad earth in the handlebar starter switch.


Cheers Steve

__________________
If I'm not working, I'll be

Chalk Two: Thanks again for the recommendation. I successfully jumped or shorted the starter relay terminals with a pair of Klein wire strippers. I am on the road again!

Steve, Hello and thanks for your input. I will inspect the starter switch when time permits. Just prior to yesterday's failure, the delayed engagement of the starter being energized nay just be indicative of a grounding issue. Today is a good day. Thanks again Steve.

Steve & Chalk Two: Hello again. I owe you a round of brews!
After inspecting the switch gear or stater switch, I have isolated the failure to be the starter switch and not the starter relay.

Steve, special thanks for directing me to this area!

For those experiencing a similar issue, the starter switch has an ignition-switched 12v on the blue with white stripe wire. once the starter switch is pressed the black wire should be energized to engage the starter.

Troubleshooting with a light or ckt tester indicated the switch was not closing properly. After exposing bare wire on the black wire, attaching the alligator clip and probing the blue w/white, the starter engaged.

Good news. I am going to remove and inspect the switch next.

Thanks again for your support!

Cheers!